[Prabhu V]

Hello all,

Kindly follow my thread…

https://www.isixsigma.com/topic/fmea-rpn-threshold/

Regards

Prabhu V.

0

[Prabhu V]

Hello Verun,

It seems that your message suggests that you have Project management related issue rather than a Quality issue.

Hence kindly reframe your question/situation or your pre-work details for better suggestion from the forum.

Just my opinion.

Regards
Prabhu V.

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[Prabhu V]

After understanding your situation on Chat support, requesting to find the below approaches to better handle the Utilization %.
a) Instead of calculating the no of actual hours spent per an agent, can calculate no of idle hours of an agent, based on pick-up time sheet (Reversal of current methodology)
b) Else, consider if any multiple chat situation then try to take out of overlapped hours spent (like if incase of multiple chat situation consider the entire time spent will be consider for a single chat or calculate the chat hours without overlapping time per each multiple chats.)
However, if sometime of considering the option b) may lead to a situation of underutilization of agent’s capability due to agents will try to avoid multiple chats due to the above reason and loss of customer participation to company, can try to award some relax norms like multiple chats hour spent will be consider as 0.5X time or more instead of 1.0X time. (or you can minus the multiple chats hours from the idle time of each agent… etc.,)
Ultimately, the situation shouldn’t bother the customer and also the agent’s capability is foremost thing to be considered while representing such data during the conflicted grounds.
Hope this will help you…

Regards
Prabhu V.

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[Prabhu V]

Hello JJ,

Requesting to follow the below links for better clarity on your issue.

15 Criteria for Selecting a Viable DMAIC Project

10 Criteria to Use for Evaluating Six Sigma Projects

My opinion: Since you’re already classifying that the process is redundant and frequency is very rare, you can think of evaluating the alternatives if feasible.

And also you have already narrow down the root cause (reason) for the issue you’re facing, hence I won’t suggest it won’t be good Six Sigma project.

Backlog clearing may be a one-time activity (no cyclic in nature), hence it won’t fit the Six Sigma criteria in general.

Regards

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[Prabhu V]

Hello Norbert,

Please share me some of case studies especially on Cost reduction (Appraisal /Opportunity) to [email protected] if possible.

Thank you!!

Regards

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[Prabhu V]

@AmitOjha,

Greetings!!

From my perspective D & M should overlap for huge success and benefits since both phases being successfully completed means the activity was half-way through.

Even in your example itself you are referring similar concepts in both phases (i.e. VOC being referred in both Define and Measure phases as “tools”).

From my opinion there was no mistake once defined something can be measured simultaneously.

However time frame should be taken into consideration means “project milestones” to be strictly met even though we do lot experiments on overlapping both Define & Measure phases.

Just my opinion.

Regards

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[Prabhu V]

Dear all,

Thanks for your suggestions!!!

Regards

Prabhu V.

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[Prabhu V]

Hello Chris Seider,

Thanks for your opinion.

I am also agreed that it is not practically feasible to set a target value, however we would to know on to how much extend we can have this NVA (non-value added) time with respect to Customer’s perspective (though the Customers have not specified any target value for this).

The alarming factor that what we have seen was some of the processes were consuming more than 100% of processing time for quality check related activities.

For such situation, we would like to propose some NVA time reduction as a guideline.

Requesting for yours/someone’s view on this if possible?

Regards

Prabhu V.

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[Prabhu V]

Hello Nandini,

I hope you underwent the training during Oct’2013.
As you’re a new GB, please try to focus on participating the projects/working problematic areas if possible.
If you’re not in such position (like college student), please try to focus general events like road traffic accidents analysis, real world situations, etc….
If you would like have a similar examples please email to me at [email protected] if you’re interested.

Thanks and regards

Prabhu V.

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[Prabhu V]

Hi,
After studying your case, I would like to mention the following:-
a) The case study clearly highlights about the communication gap from central team to other stake holders.
b) Production team can be right on their action since the practice till the moment was considering the lastest one as approved one.
c) In order to avoid the same in future central team should give the clear communication to all stake holders especially on approvals.
Just my opinion.
Regards
Prabhu V.

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[Prabhu V]

Hi,

Please use the below guidelines for your case.

For discrete data

N=(Z/E)^2*p(1-p)

Z – Constant for confidence level (like 1.645 – 90%, 1.96 – 95%, 2.575 – 99%)
E – Precision or Error – level of precision desired from the sample in units of proportion (say 5% or 0.05, if more critical then use 1% or 0.01)
p- Proportion(like 15% or 0.15 defect rate in your case)
Please feel free to post your queries in case if you want for clarifications.

Thanks and regards
Prabhu V.

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[Prabhu V]

Hi Anoop,

To answer your question in general, you can apply the sample size calculation using the discrete data method.

N=(Z/E)^2*p(1-p)

Where

N – Sample size
Z – Constant for confidence level (like 1.645 for 90% confidence, 1.96 for 95% confidence, 2.575 – 99% confidence)
E – Precision or Error (level of precision desired from the sample in units of proportion)
p- Proportion

in your case, like you wish to have the erroneous transaction to 2% from 5% (First pass yield) then, you calculation will be
N = (1.96/0.02)^2*.05(1-0.05)
N ~ 456 transactions considering that 95% confidence level being expected from the audit.
I hope this explanation can help you.

Pls feel free to post your queries

All the best!!

Regards

Prabhu V.

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[Prabhu V]

Hi,

Thanks for your reply.
However, your reply (message) still is in generic nature.
Instead of that, kindly provide your details specific to your project/activity, then only the forum members can able to understand your situation and suggest something based on their knowledge/expertise…
Off course with relevant data representation will be an added advantage.
Hoping you will understand.

Regards
Prabhu V.

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[Prabhu V]

Hi,

Are you planning to hire someone with mentioned capabilities?

Regards

Prabhu V.

0

[Prabhu V]

Hello Sridhar,

Is it possible to explain more (or elaborate) on your concept ” No purchase order, No Pay”

Thanks

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[Prabhu V]

Automated process is known for eliminating labor costs, it is one of a family of four work processes characterized (Artisan Process, Project Process, Operations Process, Automated Process)
From my opinion, it may attack all 8 types of wastes as defined by the Lean principles as below.

Transport
Inventory
Motion
Waiting
Over processing
Over production
Defects
Skills (Under-utilized)

Regards

Prabhu V.

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[Prabhu V]

Hello Sam,

On your above scenario,

a) If a client applies voluntarily without any knowledge to the bank official and pre-screening by bank was not carried out (probably through on-line platform) then it is not defect of bank (it is defect of client).

b) If a client applies through bank pre-screening process then it can be taken as defect of bank.

Hoping this clarifies the query.

Please feel free to post in case of if you required any clarifications on this.

Thanks and regards

Prabhu V.

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[Prabhu V]

Hello Abhi,

As already mentioned that the sampling techniques will be decided based on the data type you’re going to handle.

Hence if you can able to provide more details means, it will be useful to clarify your query.

For example as Mr. Baskar has explained about his situation.

Thanks and regards

Prabhu V.

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[Prabhu V]

Hello Baskar,

Thanks for your feedback.

You can very well post your query on any LSS (Lean & Six sigma) topics in this forum.

Definitely, it will be answered by someone who is having sufficient knowledge and expertise (of course if some suitable stuff with me means, surely will reply to your query)

If you want to contact me directly you can contact @ [email protected] or through LinkedIn

All the best!!!

Regards
Prabhu V.

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[Prabhu V]

Hello Baskar,

On Addressing your query, I would like provide the following details

1) The above sample size guideline is not with respect to the Population, rather with respect to the Population proportion (This formula is for calculating the statistically significant discrete data sample size).

2) And also the above guideline did not guide you on the frequency or duration of samples from the Population.

3) While considering the sample frequency/duration you can consider on some other factors like current erroneous transactions, resource availability for collecting the samples, etc.

Please feel free to post your queries in case if you want any clarifications.

Thanks and regards

Prabhu V.

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[Prabhu V]

Hello Baskar,

Kindly find the below guidelines based on your reply.

As you have not mentioned about your objective of sampling and its proportion, I am assuming your sampling objective is finding erroneous transactions in Population (89000 transactions) and erroneous proportion in Population is unknown currently (Assuming that you have 5% of transactions are erroneous).

Erroneous: 5% of transactions (p = 0.05)

Confidence level: 95% (Z = 1.96)

Sampling Precision or Error: 3% (E = 0.03)

N= (1.96/0.03)^2*(0.05(1-0.05)

N= (1.96/0.03)^2*(0.05*0.95)

N ~ 203 transactions

Please feel free to post your quires/clarifications if in needed on above.

Thanks and regards

Prabhu V.

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[Prabhu V]

Hello Mr. Jain,

Kindly find the below formulas for calculating sample size based on your inputs.
For continuous data

N= (Z*S/E)^2

N – Sample size
Z – Constant for confidence level (like 1.645 – 90%, 1.96 – 95%, 2.575 – 99%)
S – Standard deviation
E – Precision or Error
(Precision or Error is basically difference between target and actual parameter like mean, yield etc)
Estimated Mean – True Mean (like X bar – µ)
Estimated Yield – True Yield

For discrete data

N=(Z/E)^2*p(1-p)

E – Precision or Error – level of precision desired from the sample in units of proportion
p- Proportion

Please feel free to post your queries in case if you want for clarifications.

(Note: The above formulas are generic in nature, kindly support your sitaution for better clarity)

Thanks and regards

Prabhu V.

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[Prabhu V]

Hello Mr. Jain,

Sampling technique needs what kind of data (continuous/discrete) you are going to handle at first.

Kindly elaborate your query.

Thanks and regards

Prabhu V.

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[Prabhu V]

Hi,

From my point of view, even though the organization following the Six sigma concepts or not irrespective of it you can still work on any improvement area where you find there will be a scope for improvement for the organization and for your learning.

Once you have prepared some basic level concepts on the improvement area, you can very well discuss the same with your management authorities on your proposal for approval.

Based on their approval you can work and deliver the outcome which will be good for both you and your organization which you belongs to.

You can find mentors during your exercise either internally or externally (I feel that may not be an issue during the exercise)

Just my opinion.

All the best!!!

With regards
Prabhu V.

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[Prabhu V]

Hi,

Please read the article about ” The Harada Method: Reduce the Eighth Waste” in the Home page.

Regards
Prabhu V.

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[Prabhu V]

Hi,

Kaizen is a process improvement methodology, which aims at attacking the low-hanging fruits of the organization.
Kaizen as a part time activity of employee/resource is very effective & best yielding initiative in the organization.
It gives benefits to the organization as well as for the employee in terms of better morale.
PDCA, 5 Why analysis, Value addition principles are basically sounds good in your area of focus.
Best regards
Prabhu V.

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[Prabhu V]

Hi,
Pls follow the below threads, hoping that it may useful to clear your confusion

https://www.isixsigma.com/topic/continuous-data-and-discrete-data-37/

https://www.isixsigma.com/topic/continuous-data-and-discrete-data/

Best regards
Prabhu V.

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[Prabhu V]

Gaurav,
After studying the entire thread, I would like to provide the following:-
a) The purpose of audit which you would like to introduce is to ensure proper guidelines being followed in each transaction (i.e the system should not be misused)
b) Since the audit is going to be iterative once introduced it will create a awareness among the employees that there is a chance of misusing the system can be monitored and altered (like creating a ticket collector/checker mechanism in public transport like trains and buses)
As an initial step, if you’re agreeing the above points means you can do as below:-
i) First you can collect the base line data for erroneous transactions from the concerned based on their experience and history (say about 10% or 15%)
ii) Once the baseline data confirmed means you can perform the sample size calculation as mentioned above for first 1000 transactions and find the exact erroneous transaction for 99% confidence level (if critical).
iii) The outcome of step ii) is say 10% erroneous transactions then you can iterate the audit process for another 1000 transactions to get the trend after intimating the step ii) outcomes to the management/employees.
iv) If the outcome of step iii) can be lesser than step ii) means, the audit yield good results on providing a control in the system.
Of course, I have not estimated about the resources required and complexity involved in the audit process etc., into account on above (practical issues).
Hoping your doubts is clarified.
Regards
Prabhu V.

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[Prabhu V]

Gaurav,

Can you elaborate your queries for better understanding (Hoping that I have given all the assumptions used in the above example in detail.)

Regards

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[Prabhu V]

Hi Gaurav,

To answer your question in general, you can apply the sample size calculation using the discrete data method.

However, you should have some pre-work data for this method (say for example, from the previous analysis about 10% of transactions were erroneous)

If you have similar situation, then you can apply the discrete data logics as follows:

N=(Z/E)^2*p(1-p)

Where

N – Sample size
Z – Constant for confidence level (like 1.645 for 90% confidence, 1.96 for 95% confidence, 2.575 – 99% confidence)
E – Precision or Error (level of precision desired from the sample in units of proportion)
p- Proportion

in your case, like you wish to have the erroneous transactions to 5% from 10% (previous analysis data) then, you calculation will be
N = (1.96/0.05)^2*.10(1-0.10)
N ~ 139 transactions considering that 95% confidence level being expected from the audit.
I hope this explanation can help you.

Pls feel free to post your queries

All the best!!

Regards

Prabhu V.

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[Prabhu V]

Hi Abinash,

Can you confirm whether your objective is to obtain attribute agreement analysis from both CMM?

(In general, you can follow the procedure as per prescribed guidelines like AIAG)

Regards

Prabhu V.

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[Prabhu V]

Hi Vineet,

Are you aware of QFD techniques, I hope it will be helpful for your situation.

Please find the attachment regarding QFD.

Best regards

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[Prabhu V]

Hi Chris,

Thank you for your intimation.

The current sequence is (at least 10 parts with 3 operators & 3 trials)

Sorry for the inconvenience to all.

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[Prabhu V]

Hi Daniel,

In your above query, I would like to post the following:-

a) Are you conducting an attribute gage study (since you have mentioned that “for detecting the bad parts”
b) Or else conducting for variable study (I hope you may aware that the process and objective is entirely different for both)

In addition, I would like to update you on the AIAG’s MSA fourth edition update, which states that the revised requirements for the MSA study (at least 10 operators with 3 parts & 3 trials)

Please feel free to share your thoughts/comments.

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[Prabhu V]

Hi,

From your query the population prevalence rate of 20% can be the proportion on the discrete sample size formula = (Z/E)^2*p(1-p), where p is proportion.
E is the margin of error described as “the level of precision desired from the sample in units of proportion” (generally 5% or 1% on critical situations).

If my above opinion were correct, on the above situation the sample size requirement would be 246 samples on 95% CI and 5% error. (6146 samples on 95% CI and 1% error)

Kindly confirm do you agree on it.

Thanks.

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[Prabhu V]

Hi,

you can review the following dicussion and also my thread for your query.

https://www.isixsigma.com/topic/military-qualifications/

All the best!!!

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[Prabhu V]

Hi,

Brainstorming and CTQ drill down tree can be useful for your situation if you have a clear process map (or SIPOC).

All the best!!!.

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[Prabhu V]

Hi,

As per industry experts the best place to get certified is through a Company or through a Non-profit institutions (like university etc.,).

Based on your situation, it is always advisable to check with your locality for the same.

All the best!!!

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[Prabhu V]

Hi,

I would like put the following observations(hoping that the data collection plan was framed properly with validation like identification, operational definition, sampling plan, Stratification etc.,)

a) Sample sizes across the categories are small to predict the issue (If possible please try to get as much data as possible).
b) With the collected data, Parato chart can be useful to prioritize the top areas to be taken for further study (for fixing CTQs – Critical to the problem/quality).
c) Once the CTQs are fixed means, please develop the C&E (Cause & Effect) diagrams to find the root causes for the CTQs like for obtaining profiles if it took more time means please try to find the causes and once identified causes means please try to find the solutions in terms of alternates like introducing referral scheme bonus for employees, internal transfer etc.,
d) Bench marking the CTQs with industrial value also seems to be good to know the gap of company with respect to the industrial average if available.
e) And if required please try to eliminate any abnormal value (like for a particular skill set it may be a huge time consuming process means that the abnormal value no need to be used for the study, only on exceptional cases)

I hope further level introspection being required to fine-tune the situation.

Best of hard work.

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[Prabhu V]

@sowmyas: Hi,

You can very well post your queries in this forum for suitable suggestions.
If you want to contact, pls find my email as [email protected]

regards

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[Prabhu V]

Hi,

Can you pls explain what is ADD (is it Attention deficit disorder?)

regards

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[Prabhu V]

Hi,
One basic clarification is needed; do you want to work on lead-time reduction or cycle time reduction?
Generally, cycle time reduction seems to be good approach than lead-time reduction.
Pls find the definition for Cycle time:
Cycle time is the total time from the beginning to the end of your process, as defined by you and your customer. Cycle time includes process time, during which a unit is acted upon to bring it closer to an output, and delay time, during which a unit of work is spent waiting to take the next action. (Hence lead time should include Cycle time plus additional time like delay time etc.,)

Regards

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[Prabhu V]

Hi,

If you are preparing for ASQ exams, you can find the same in their website itself. (you can find some groups in Linkedin also)

regards

0

[Prabhu V]

Hi,

Lean is best suited for process related activities like meeting demand-supply model.

Six sigma is basically a problem solving methodology.

Hence, it is your choice on which you need to focus.

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[Prabhu V]

Hi,

From your lengthy post, it is very clear that you want to work from scratch.

As you are already a MBB and well known about DMAIC concepts, I would like intimate few thoughts I have come across while reading your post.

a) Basically Six sigma’s DMAIC concepts, for problem solving purpose in an organization like, if you want to improve a good thing (productivity, customer satisfaction, market share) and if you want to reduce a negative thing (defects, rejections) then “DMAIC” is the best tool to use.
b) If your aim is to develop process, the way you are working and to meet customer demand & supply properly, then “Lean” techniques are best tool to use.
Of course, in your above post you have not mentioned about the type of industry and product details etc. which may have influence on the concepts/tools.

Since your above post expresses your long-term vision or perspective, definitely you should have some short-term goals also to initially start up or to focus on particular area.

Any organization is currently looking for “customer satisfaction/delight”, hence at the initial start up you can also look for the same and work on it.

Later you can switch over to similar areas of improvement.

Best of hard work!!!!!

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[Prabhu V]

Dear all,

I would like to intimate all here that cause & effect matrix (XY matrix) and cause & effect diagram (Ishikawa’s or fish bone diagram) are different.

Of course, both aims at same area (root cause identification) however according to me the methodology is different.

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[Prabhu V]

Hi,

For applying ASQ certification, you need minimum valid project completion guidelines (in case of CSSBB).

Of course, ASQ is most recognized certification in six sigma.

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[Prabhu V]

Hi,

From my understanding, your objective is on the opportunity cost.

For that, you need to work on how to improve the out of stock items.

Of course, for the same you need to collect the relevant information.

However, some of your assumptions seems to be vague like will the customer wait for your product etc., which can’t be decided since it may not be predicted properly (may be the brand image of your organization, necessity for the customer on the product and availability of product in market etc will influence to choose alternatives incase of out of stock with you)

Hence you may collect the information from past what are the parts went out of stock, and projecting it under Pareto chart and other tools will help to decide the critical items.

Once you have identified on some grey area then you can work on those areas which will definitely improve the situation.

For just my opinion.

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[Prabhu V]

Shiva,

On the above post, the details regarding the sample selection is found missing.

Can you provide information on how are you deriving the samples from the vendor?

Is your sample size statistically significant?

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[Prabhu V]

Hi Shiva,

Based on your base inputs, it seems that Chi-square test for goodness of fit can be useful for your situation.

Please try for it.

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[Prabhu V]

@anastasia:

Please do share your contact email to [email protected]

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[Prabhu V]

Hi,

Please follow the below formula on your case

Sample Size n=(1.96/ Precision)^2 * p(1-p)

Where n- minimum sample size required
p- estimate of proportion of the of the population
Precision – Level of precision desired from the sample in units of proportion
1.96 – constant representing a 95% confidence interval

So you consider it on your case, the required sample size would be 62 samples (61.4656)

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[Prabhu V]

@Mike,

I fully agree with your above comment. However my post is as true in some areas as I have known (Of course it is not the scope of this forum to work on it).

Thank you for your comment.

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[Prabhu V]

@cseider

I just put the generally followed learning methodology in some places.
As you said the scope of GB course is not only restricted to the teaching sessions.

However, from my experience the expertise level for doing GB project and BB project is entirely different.

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[Prabhu V]

Hi Waleed Raza,

Welcome!

Kindly post your LSS query on this platform

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[Prabhu V]

@ Tom U: From my understanding, one can directly do BB course without doing GB course since the criteria for GB course will be only theoretical learning and for BB course is both theoretical and practical learning (in generally followed learning methodology)

However there are lot of differences in BB course like team management, project management etc.,

Hence based on one’s current work profile, education and experience can do the direct BB course.

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[Prabhu V]

Hi Priyanka,

The formula for determining project ROI is:

Project ROI = ((Financial Gain or Loss – Project Cost) / Project Cost) X 100.

From my experience, the ROI indicator can be collected for each year until the project’s survival in the organization.

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[Prabhu V]

Karthik,

Please find the definition for both terms,

Lead time: The amount of time, defined by the supplier/service provider, that is required to meet a customer request or demand. Lead-time is generally considered as the time between the Customer’s request initiation to Customer’s request fulfillment.

Turn around time: This time is in order to get a job done and deliver the output , once the job is submitted for processing center according to the customer request.

In nutshell, TAT generally takes about the time requirement to meet a customer demand internal to the processing center and Lead time considering both internal and as well as external to the processing center.

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[Prabhu V]

Hi Bhargav,

As per FMEA guidelines based on the fourth edition, pls find the following regarding the RPN.

i) Threshold values for RPN are not recommended.

However,

ii) Action can be taken prioritized based on Severity and RPN.

iii) Severity ranking of 9 or 10 requires special attention irrespective of RPN.

Hoping this will help you!!!

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[Prabhu V]

@Mike-Carnell: Thank you very much for your appreciation. It will help me to fine-tune my blogs in this forum.

@drock112: Congrats for to sucessfully complete your project and hopefully to claim the benefits as a Black belt project.

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[Prabhu V]

Hi,

From my opinion,

There are lot of differences in doing green belt and black belt projects.

Black belt projects as you have mentioned aiming for larger scale and much more benefits than a green belt project. (of course it may vary depends on industry to industry)

Hence considering the workload and data management it is better to split the activity to such small groups based on area of problem/improvement.

Team management is a very important key task as a project leader in a black belt project. The leader should ensure the team members expertise on the subject matter, hence if required need to train them.

Best of hard work!!!

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[Prabhu V]

Hi,

Based on your original post and comments, please find the below.

> Process capability study is necessary for in order to
i) Measure the process involves only common cause of variation not special cause of variation and
ii) Compare the variability with a proposed product tolerance.

>Process capability index (Cp & Cpk) is the statistical measure of process capability (i.e the ability of a process to produce output within specification limits)

>As HD is CTQ parameter as per initial query incase of any variation in individual HD it may be captured on some tools like multi-vari charts (capable of studying about Positional, Cyclical, Temporal variation).

> Control charts are very much suitable for studying the process as you have mentioned that incase of two separate process were involved in the activity.

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[Prabhu V]

Hi,

I hope you need to post the query on your project. What is your area of excellence, problem area etc, etc,

For Mentor, if you belongs to any organization then you can find the suitable person from the organization (it will be really helpful on your project)

Best of hardwork!!!

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[Prabhu V]

@Lebowski

Thank you very much for spending your valuable time on reviewing my posts in the forum.

I hope still you need to review some more of my posts in this forum (or shall I consider that at least those comments are relevant to the questions as well as meeting your standards)

Thanks again !!!

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[Prabhu V]

@Mike-Carnell

Thank you for accepting that my comment is true and please find my reply for those two comments

1. “I hope you have completed your Six sigma certification from an Institution rather than from an Organization (may or may not be you belong to).”
Reply: Of course above my comment is not any kind of interview question. Since the person asked about what sort interview questions may be expected after completing the certification, it is clear that the person heading for an interview panel externally (not from the organization belongs to)

2. “A strong person on the fundamentals and as well as knowing recent updates in the curriculum are the key to succeed in any tough interviews.”
Reply: It is very tedious to figure out all the questions being asked by an Interviewer in the panel(hoping that it depends on lot of parameters), hence I have suggested that the key to succeed in the interview panel, kindly review my statement above if you still feels that the above comment is not relevant, please share your thoughts (I always like constructive criticism)

Thank you for spending your valuable time!!!

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[Prabhu V]

@Mike-Carnell:

Thank you for your serious comment.

Since the owner of this post has has asked about what sort interview questions may be expected at the interview panel, I have mentioned like that.

I am also anxiously waiting to see your reply!!!

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[Prabhu V]

Hi,

Pls find the reply based on my understanding.

Answer 1 :

To calculate process capability for OD and ID:
a) Pls set up a data collection plan for every day from the production and using both USL & LSL and can calculate both Cp & Cpk separately for OD & ID
b) On ovality like above both Cp & Cpk can be calculated using LSL =0.00 mm and USL = 0.03 mm

Answer 2:

For HD (Hole Diameter)
a) If HD is critical to quality then calculating the process capability for each hole of washer using LSL =2.98 mm and USL = 3.02 mm being required, instead of average hole diameter of the washer.
b) As you have mentioned calculating the average of 8 hole’s diameter is hard to find where is the variation present if HD is CTQ parameter.

Answer 3:
a) From my understanding we can able to calculate Cp & Cpk values per CTQ parameter and it is useful for further study ( I am not sure about your understanding to study Cp & Cpk for machine wise)

Pls do share your thoughts also.

Prabhu V.

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[Prabhu V]

@Sigmadiva

I hope you have completed your Six sigma certification from an Institution rather than from an Organization (may or may not be you belong to).

Interest for learning new things is very important rather than where you have completed your certification in general.

In general, the interview questions regarding the Six sigma will be primarily to test the excellence of your curriculum learned or the project work you have carried out.

A strong person on the fundamentals and as well as knowing recent updates in the curriculum are the key to succeed in any tough interviews.

Best of Hardwork!!!

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[Prabhu V]

Hi,

“Kaizen” meaning in English as “Change for goodness”.

Any effort taken in an organization for the purpose of changing the current process for the better process can be known as Kaizen effort.

The current process may be poor or doing well. The Kaizen is all about looking for further scope in the current process if available.

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[Prabhu V]

Hi,
Based on your reply, I would like to suggest the following:-

Assumption: Quality related parameters are high important than quantity related parameters.

Op. def.: In order to decide the footage quality you may define the binary points for your quality definitions like Ok or Not Ok.

Like if any footag’s Sharpness – Ok, Contrast – Ok, Brightness – Ok, Colour – Ok, Proper frame – Ok, etc. then the Quality rating of that footage is Very Good otherwise depends of priority you may define the Op. def for Good, Average, Poor and Very Poor. (the other parameters like Defect def etc may be same with your observation)

By doing so you can get quality rating on quality definition for your current defects (rejected footages), On which data you may do suitable analysis as you have mentioned (like Parato etc.,)

I hope this will project more information with less efforts.

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[Prabhu V]

Hi,

From my understanding on your project, I strongly recommend to collect your data as continuous data instead of discrete data.

As the thumb rule, collecting and analyzing the ordinal scale data will require more efforts comparing with continuous interval scale data.

As per your ppt on CTQs,

A) On quality area instead of ordinal scale data you may try to collect the footage data as like its technical specifications (as you have already mentioned as Sharpness, Contrast, Brightness, Colour, Proper frame – even you may set a specification limit for those parameters and do the evaluation based on the technical specifications instead of ordinal scale parameters: good, average and poor since it may be misleading sometimes)

B) On quantity area it may be purely with respect to the subjected matter hence you may still continue to use the ordinal scale data or you may try to use Kano model analysis.

And I strongly believe that for editing process your CTQs with respect to Quality is more important than Quantity area. (May be Quantity area is critical when making final decision on whether to broadcast the footage or not)

Pls feel free to post your further queries.

Best of hard work for your project.

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[Prabhu V]

Hi Miguel,

From your explanation, I would like to state the following points

A) Specification limits for Process capability:
As you have stated you have the customer voice of 97% average yield (with +/-3% tolerance), hence your USL =100% and LSL=94%.

Based on the above you may calculate the Process capability.

B) Yield calculation:
You have mentioned that the yield has been calculated on the based on DPO, pls find the formula for classical yield.

Classical Yield or First pass Yield = 1-(Total no of rejections/Total no of production from the process).

I hope your phenomenon need to be modified since you have mentioned that you have used defective concept for yield calculation. (DPO study is irrelevant for yield calc.)

Based on your information, your classical yield =1-(36/259)% = 86.1%

Since your customer may accept only min 94% yield, the gap to target is 7.9% (likely gap to target will vary for mean and upper limit).

Kindly consider the above.

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[Prabhu V]

Hi Neal,

I hope now you will have some fundamentals for your project. Pls work with that.

Incase of any query, pls feel free to post and get it clarified by the suitable exe.

Best of hardwork!!!

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[Prabhu V]

Yes. Gauge R&R is worth only. Since measurement system can be source for variation. What if your mesurement system shows that all good products as bad one.

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[Prabhu V]

Hi Neal,

I hope you are not in initial stage of your project.
As per your quote, you may be having some VOC on defects. Based on that you may calculate the process capability.

Since you are already identified some opportunities, pls try to collect the relevant data to show whether you’re in the right direction.

Data driven nature is the uniqueness of LSS projects. Lot of hidden truths will come out from the process.

All the best

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[Prabhu V]

Hi,

To add the above points on certified v/s non-certified, Certification is the process of recognition for the work. There are more people in the world who may be successful but not certified on any particular. Only case-to-case analysis considered relevant.

Completing both theoretical and practical approach is considered relevant on any course/training/skill procurement…..

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[Prabhu V]

@cseider – I hope Mazen’s question was formulated well. He wants to know about whether FPY and FTY are both same or different.

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[Prabhu V]

Hi,

Can you pls elaborate your query with what is the main objective and others…..

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[Prabhu V]

Hi,

From my understanding on the hospital industry, may be the admission process can be classified as “in-patient”, “out-patient” and “Emergency”.

As “Emergency” is unavoidable situation and the process to be simple and quick, we need a special admission process for the same.

After that to follow, only “Out-patient” admission process with pre-screening techniques to all other “non-emergency” candidates and later if required the same candidate can be transferred to “In-patient” admission process.

May be this method could be efficient from my perspective.

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[Prabhu V]

Hi,

According to my understanding, I hope you’re aiming to reduce the followup calls for an particular issue like if an query has been raised to the operator means the same need to be resolved during at that instance itself.

Hence the classical “First time resolution” metrics could be suitable for you as of now. (like avoiding followup calls from a customer for a particular issue)

DPMO studies can be varied depends on type of project/query/product etc.

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[Prabhu V]

Hi,

From my understanding the Pareto principle 80:20 rule applied here can be misleading your study if the 20% of part representing extreme more days (since it may be a hidden cost to the management).

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[Prabhu V]

Hi,
According to me, First pass yield represents that how many number of good products are delivered from the process wrt to the total number of products produced without taking into the account of reworks in the process on a particular batch/day/time etc.

First time pass sentence also describes the above.
May be some industries will use FPY and some other industries will use FTP.

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[Prabhu V]

Hi,
Can you please elaborate your query in detail on LSS(Lean & Six sigma) perspective?

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[Prabhu V]

@Mike Carnell – Thank you for your post. I understood the situation. I will consider this in future situations. Thanks

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[Prabhu V]

@Sriram – thanks for the information and i believe that the above mentioned formula only applicable for continuous data, where as for discrete data one more parameter called estimate of population proportion to be taken care.

Like

n=(Z/Precision)^2*p(1-p)

p – estimate of population proportion.

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[Prabhu V]

Hi to all!
During my study on sample sizes, I remember that the term Precision was used on it.
Like for example for the continuous data sample size calculation, the formula as follows:

n= (Z*S/Precision)^2

Is this a new formula?
Can someone explain?
Thanks in advance.

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[Prabhu V]

  @Mike-Carnell – Thank you for your feedback. As you have stated “Gemba” is a Japanese word means of “the work place” in English.

For users to avoid the confusion, I have mentioned the word and its meaning in English in the same sentence itself.

May be a “()” could be an alternate i believe, thankyou for the quote.

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[Prabhu V]

Hi,

According to me, any project work need to be initiated for the following objective

a) To improve the good work like productivity, quality, Customer satisfaction etc.,
b) To reduce the negative work like rework, defect, COPQ etc.,
c) To Widen the scope of work like benchmarking, market share widening etc.,

Hence pls try to work on the above irrespective of any area of work.

Incase of any assitance to kindly contact your organisation’s belts or any external source like this portal.

Best regards

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[Prabhu V]

Hi to all,

The 5S technique was developed for various purposes apart from what it was actually describing like Sorting, stabilizing, Shining, Standardizing and sustaining.

Like the one who following the 5S technique will get lot of benefits because of the disciplined approach, the Safety also one of the benefit as the 5S technique minimizes the risks involved in the gemba, the workplace.

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[Prabhu V]

Hi,

According to me, when the time you started talking about “controlling the variability and DMAIC approach” then it by default comes under the LSS framework.

Data driven approach is best & effective approach for solving problems basically from the variation area.

Hence i strongly recommend to follow the LSS principles in your focused problem area.

Best Wishes.

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[Prabhu V]

@Stuartsharman – Hi, Can you please put your queries or problems in detail so that the specific answers to those queries is possible.

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[Prabhu V]

Hi, I feel that the query needs some more basic information on the problem or situation.

Will you provide some more information about the problem?
This will be useful to answer your query.

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[Prabhu V]

Hi, According to me for the current situation on controlling the waste in the process the first pass yield and throughtput yield studies of process is good.

This studies will give clear picture about of cost of poor quality in the process and this will be the fundamental/basic step in order to start any project.

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[Prabhu V]

Hi,

According to me, confidence interval related stuff can help better in the situation.

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[Prabhu V]

Hi,

Adding to the above point, always an user has to ensure that the user is using the correct control chart for the situation faced by the user.

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[Prabhu V]

Hi,
From my opinion the necessary activity to do is defining the process which going to established. May be SIPOC, Process Map etc., kind of basic tools need to be considered at this stage. Once the process is known then VSM can be implemented.

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[Prabhu V]

Hi,

The formula the confidence interval is : P+/- Z alpha/2 * SQRT ((P *(1-P)/n)
Where P is Population proportion
n is sample size.

From the above formula, it is clear that CI is function of Std deviation (Z alpha) and as well as the subgroup sample size.

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[Prabhu V]

Hi, According to me you can learn the theoretical part of concepts using online mode. However Six sigma kind of concepts are need to be practically applied then only the learner will actually learned concepts thoroughly.

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